Chevrolet Astro Problems

Outside Door Handles May Break on Chevrolet Astro

Problem Description and Possible Solution

The outside door handles are prone to breaking—all doors are affected by this condition.

(84 people reported this problem)

Chevrolet Astro Vehicles With This Problem

RepairPal Verified
Average mileage: 143,650 (13,115–258,000)
16 model years affected: 1990, 1991, 1992, 1993, more1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005
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Viewing 1-20 of 40 comments
rear door handle snapped off - also, doors are stuck closed after spring assembly seems to have fallen apart inside the door.
Both door handles broken....have ordered new ones. Seems to me another Government Motors (GM)design flaw..!! Can't wait for Nomobama care to start up...(once we can ACTUALLY sign up for it)...on that gubmnt' web site..!!
First driver side at about 140,000 and then pass side at 150,000 outer door handles broke and had to be replaced.
This is a common problem in Chevys. My family has owned several Suburbans & Chevy trucks with the same problem.

The issue is not the door handle itself, but the spring that releases the door wears out, causing passengers to pull again and again on the handle because the door is hard to open. You can replace the handle, but without replacing the spring, it will happen again.
I had the same problem with the driver's door. You can buy the replacement handles at the auto parts store. I followed the instructions in my Haynes manual with some success. It took myself longer to than what the instructions stated, and I had to disassemble the lock assembly to put everything back together. This part wasn't apart of the instructions.
Door was unlocked and not frozen. I simply pulled on the handle as I always do and it snapped off.
Drivers side door exterior handle, lock rod kept coming off. I went to my local Chevy dealer. One of the guys gave me 4 of both size nylon washers
Bottom under handle broke first.Then handle broke all the way drivers the process of having repaired
Every Astro van we've used in our business has had major issues with door handles breaking. '91,'93,'96. Chevrolet needs to quit using cheap pig iron to make these; we've cleaned out area junk yards of their chevy astro door handles. Not so hard to fix, but pain in butt to find used. Have tried new replacements and they are just as inferior.